A LT E R N AT O R S RANGE A A G A A K A A K c o m p a c t A A N c o m p a c t A A T A LT E R N AT O R S ISKRA The technical performance of Iskra alternators is based on long-term relationships with the customers, their high requirements and expectations and our own long-standing experience in development and production. We control quality using ISO 9001 and QS-9000 standards. The entire process from customer requirement and expectation, through development and production is planned and controlled in detail. High operating reliability is assured by optimising the design for use in different operating conditions, together with numerous validations of different alternators in Iskra's own laboratories and on vehicles. Alternators are air-cooled synchronous three-phase generators with claw poles and a built-in semiconductor rectifier. A three-phase stator winding is connected to the three-phase rectifier bridge with power rectifier or Zener diodes. The rotor coil is connected to the slip rings with brushes that conduct the excitation current. Alternators are selfexcited through excitation diodes or they are excited directly by the battery. The voltage regulator can be either built-in or separately mounted. The negative terminal is normally connected to the chassis. Iskra Avtoelektrika keeps abreast of all technical innovations in the field of alternators. Its staff are aware that energy conservation in vehicles is an absolute necessity. The results are different families of alternators designed in modern compact versions with internal fans in parallel with families of conventional design using external fans. Modern versions of rectifiers and specific multifunction regulators are also available. Different versions of alternators meet very high specifications in terms of resistance to salt spray, humidity, water, mud, dust, vibrations, high and low temperatures and aggressive liquids. They are also designed to meet electromagnetic compatibility and other international directives and standards. They are produced using ecologically sound technologies and environmentally friendly materials. Iskra alternators are designed to meet a wide range of engineering specifications and applications. They are used on petrol and diesel engines in the automotive industry, on trucks, buses, tractors, construction machinery and in other applications. Different solutions of our alternators are defined taking into account the demands of each application and are designed for long life, maintenance free operation under extreme conditions. CLASSIFICATION OF ALTERNATORS Alternators type AAG stator diameter 108 mm Alternators type AAK stator diameter 125 mm Alternators type AAK compact stator diameter 125 mm Alternators type AAN compact stator diameter 142 mm Alternators type AAT stator diameter 165 mm 14 V , 2 8 V A LT E R N AT O R S ALTERNATORS 14V 100 90 80 AAN compact 70 60 7.3kg Output in Amps. at 1800 RPM 50 AAK compact 40 AAK 30 20 5.3kg 4.7kg AAG 3.5kg 10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 140 150 160 Output in Amps. at 6000 RPM ALTERNATORS 28V 100 90 AAT 80 70 60 14kg Output in Amps. at 1800 RPM 50 AAN compact 40 7.3kg 30 AAK compact 20 5.3kg AAK 10 AAG 4.7kg 3.5kg 0 10 20 30 40 50 Output in Amps. at 6000 RPM 60 70 80 90 100 110 120 130 A LT E R N AT O R S AAG APPLICATIONS Low output powers make it possible for the alternators to be built into systems with low electrical requirements. Small dimensions allow installation on all types of combustion engines used on small tractors, small agricultural machinery, stationary engines and some other applications. DESIGN The alternator is a three-phase, 12-pole synchronous self-excited generator with builtin rectifier and regulator and cooled by an external fan. Various design solutions are available depending upon the application: insulated, marine, dustproof and other versions. Cooling The integral fan provides effective through cooling of the alternator. Two different fans are available, for CW and CCW direction of rotation. MAIN TECHNICAL DATA Type AAG Nominal voltage 14V 28V Nominal current 33A - 50A 18A Stator diameter 108 mm Weight ~3.5 kg without pulley Max. speed 18,000 RPM Regulator Built-in or separate Hybrid technology Pulleys and drive Different types according to end brackets customers' requirements Terminals Screw and/or blade terminal Drive end bearings Type 6203 – 2RS Rear end bearing Type 63001 Power diodes Press fit rectifier diodes or Zener diodes Protection of the slip Protected against access by a wire rings and brushes or splashing water (IP 44) Protected against ingress of solid foreign matter and powerful water jets (IP 56) Ambient temperature From - 40ºC to + 110ºC Rotor The rotor winding fixed between the claw poles provides excitation of the alternator through slip rings. For particularly dusty environments slip rings and brushes are additionally protected. Rectifier Press fit rectifier diodes or Zener diodes are mounted into protected heat sinks. Zener diodes protect the loads on the vehicle against overvoltages from the alternator. Regulator The regulator incorporating the brush holder is built into the alternator. The regulator is produced using thin-film hybrid or microelectronic technology. Monofunction or multifunction is available depending upon the requirements of the application. The highest quality brushes ensure long life of the alternator. Brackets - Bearings - Pulleys Brackets, bearings and pulleys are made according to the customers’ requirements. A range of special sealed bearings makes it possible to design alternators for specific installations, operating in the harshest conditions whilst achieving long, maintenance free life. Electrical terminals Electrical terminals are according to the customers’ requirements. A LT E R N AT O R S AAG CROSS SECTION 3 Pos 1 … Pulley Pos 2 … Drive end bearing 4 5 6 7 8 9 10 2 11 1 12 Pos 3 … Fan Pos 4 … Drive end bracket 13 Pos 5 … Stator Pos 6 … Rotor o 108 mm 14 Pos 7 … Rear bracket Pos 8 … Snap ring 15 Pos 9 … Sealing felt Pos 10 …Rectifier 16 Pos 11 …Slip rings Pos 12 …Terminals B+, W, D+ 17 Pos 13 …Capacitor Pos 14 …Rear bearing Pos 15 …Brush Pos 16 …Brush holder with voltage regulator 123 mm Pos 17 …Rubber gaskets CHARACTERISTICS I(A) I(A) 20 60 18A 50A 15 45 35A 33A 30 10 5 15 U=const.=27V To=23ºC±5ºC U=const.=13V To=23ºC±5ºC 0 0 0 0 1000 2000 3000 4000 5000 6000 7000 1000 2000 3000 4000 5000 6000 7000 n(RPM) n(RPM) I (A) at 1800 RPM 6000 RPM 14V 33A 1150 15 32 14V 35A 1250 13 35 14V 50A 1250 20 48 CONNECTION DIAGRAM 28V 18A D+ B+ B- W DREGULATOR DF G I (A) at n ° (RPM) D+ I (A) at I (A) at n ° (RPM) 1800 RPM 6000 RPM 1200 8 18 A LT E R N AT O R S AAK APPLICATIONS High output power alternators to satisfy the needs for electrical energy in a wide range of applications: • for cars • for commercial vehicles • for heavy-duty applications • for special applications DESIGN The alternator is a three-phase 12-pole synchronous self-excited generator with builtin rectifier and regulator and cooled by an external fan. Depending upon the purpose of the installation, various versions can be supplied: insulated, marine and other versions according to special requirements. Cooling An integral fan provides effective through cooling of the alternator. Two different fans are used depending upon the required direction of rotation. MAIN TECHNICAL DATA Type AAK Nominal voltage 14V 28V Nominal current 45A-80A 35A – 50A Stator diameter 125 mm Weight ~4.7 kg without pulley Max. speed 18,000 RPM Regulator Built-in or separate Mono or multifunction Hybrid or microelectronic monochip technology Pulleys and drive Different types according to customers' end brackets requirements. Terminals Screw and/or blade terminal Drive end bearings Type 6203 / 6303 / 6304E / 6403-2RS Rear end bearing Type 6201-2RS Power diodes Rectifier or Zener diodes Protection of the slip Protected against access by a wire or rings and brushes splashing water (IP 44) Rotor With regard to the requirements of the installation and the operating conditions, different protection levels are provided for the slip rings and brush compartment. Rectifier A three-phase bridge circuit with power rectifier diodes and excitation diodes provides D.C. output currents and excitation of the alternator. It is possible to use Zener power diodes to protect loads on the vehicle against alternator overvoltages. Regulator Regulator with brush holder is fitted to the alternator. They are made in thin-film hybrid or microelectronic technology. With regard to the requirements of the application they may be monofunction or multifunction. The highest quality brushes ensure long life of the alternator. Brackets - Bearings - Pulleys Brackets, bearings and pulleys are made according to the customers’ requirements. A range of special sealed bearings makes it possible to design alternators for specific installations, operating in the harshest conditions whilst achieving long, maintenance free life. Protected against ingress of solid foreign matter and powerful water jets (IP 56) Ambient temperature From - 40ºC to + 110ºC Electrical terminals Electrical terminals are according to the customers’ requirements. AAK A LT E R N AT O R S CROSS SECTION 1 Pos 1 … Pulley Pos 2 … Drive end bearing Pos 3 … Fan Pos 4 … Drive end bracket Pos 5 … Stator with winding Pos 6 … Rotor Pos 7 … Rear bracket Pos 8 … Snap rings Pos 9 … Sealing felt 2 3 4 5 6 7 8 10 9 11 12 13 o 125 mm 14 15 16 Pos 10 … Rectifier with diodes Pos 11 … Protective cover 17 Pos 12 … Slip rings Pos 13 … Terminals B+, D+, W 18 Pos 14 … Capacitor Pos 15 … Rear bearing Pos 16 … Brush Pos 17 … Brush holder with voltage regulator 135 mm Pos 18 … Rubber gaskets CHARACTERISTICS I(A) I(A) 80A 80 60 75A 70 50A 65A 60 45 55A 40A 50 35A 45A 40 30 30 20 15 U=const.=13V To=23ºC±5ºC 10 U=const.=27V To=23ºC±5ºC 0 0 0 1000 2000 3000 4000 5000 6000 7000 0 1000 2000 3000 4000 5000 6000 7000 n(RPM) I (A) at I (A) at n ° (RPM) 1800 RPM 6000 RPM 14V 45A 1000 28 45 14V 55A 1100 27 54 14V 65A 1100 30 65 14V 75A 1250 34 74 14V 80A 1350 29 80 n(RPM) I (A) at I (A) at n ° (RPM) 1800 RPM 6000 RPM 28V 35A 1200 15 35 28V 40A 1450 12 40 28V 50A 1550 5 50 L CONNECTION DIAGRAMS D+ B+ B- W B+ DREGULATOR BREGULATOR DF Multifunction regulator G G DF D+ Monofunction regulator EX A LT E R N AT O R S AAK compact APPLICATIONS • for passenger cars • for commercial vehicles • for heavy-duty applications • for special applications F • • • • • • eatures high specific power and efficiency small dimensions low weight low noise level higher protection against accidental contact long life operation DESIGN The alternator is a three-phase, 12-pole synchronous self-excited generator with two internal fans and built-in regulator and rectifier. The compact construction and carefully selected materials assure improved technical characteristics and long life, service free, operation even under the harshest conditions of high and low temperatures, salt spray, humidity, water, dust, vibrations, aggressive liquids. MAIN TECHNICAL DATA Type AAK Compact Nominal voltage 14V 28V Nominal current 70A-120A 40A – 60A Stator diameter 125 mm Weight ~5.3 kg without pulley Max. speed 20,000 RPM Regulator Built-in or separate Monofunction or multifunction Microelectronic technology Pulleys and drive Different types according to customers' end brackets requirements. Terminals Screw and/or blade terminal Drive end bearings Type 6303, 6304E, 62304E Rear end bearing Type 6003 Power diodes Press fit Zener diodes Protection of the slip Protected against ingress of solid foreign rings and brushes matter and powerful water jets (IP 56) Ambient temperature From - 40ºC to + 110ºC Stator The stator has a three-phase winding on a laminated pack. The selected design and high filling factor of the stator slots provides improved cooling, low noise and high output characteristics. Cooling Two internal fans positioned on the claw poles provide more effective cooling with lower noise and higher protection against accidental contact as well as higher output. Rotor Smaller slip rings provide higher brush durability, even at high speeds. Encapsulated slip rings offer increased durability of the alternator. Rectifier Sandwich construction of the rectifier with press fit Zener diodes provides the low temperatures of the rectifier diodes, high resistance to vibrations and protection of loads on the vehicle against alternator overvoltages. The installation of the rectifier on the outer side of the rear end bracket ensures flexible arrangement of all types of terminals. Regulator The regulator together with the brush holder is assembled on the rear end bracket. Regulators use microelectronic technology and are mono or multifunction. The highest quality of brushes ensure long life of the alternator. Brackets - Bearings - Pulleys Brackets, bearings and pulleys are made according to the customers’ requirements. A range of special sealed bearings makes it possible to design alternators for specific installations, operating in the harshest conditions whilst achieving long, maintenance free life. Electrical terminals Electrical terminals are according to the requirements of the customers. A LT E R N AT O R S AAK compact CROSS SECTION 1 2 3 4 5 6 7 8 9 Pos 1 … Pulley Pos 2 … Drive end bearing Pos 3 … Drive end bracket Pos 4 … Stator with winding 10 o 125 mm Pos 5 … Rotor Pos 6 … Rear bracket Pos 7 … Rectifier with diodes 11 12 Pos 8 … Protective cover 13 Pos 9 … Terminals B+, D+, W 14 Pos 10 …Rear bearing Pos 11 …Slip rings Pos 12 …Brush Pos 13 …Brush holder with voltage regulator 140 mm Pos 14 …Rubber gaskets CHARACTERISTICS I(A) I(A) 120 80 120A 70 105 95A 90 80A 75 60A 55A 50A 45A 40A 60 85A 50 70A 60 40 45 30 20 30 U=const.=13V To=23ºC±5ºC 15 U=const.=27V To=23ºC±5ºC 10 0 0 0 0 1000 2000 3000 4000 5000 6000 7000 1000 2000 3000 4000 5000 6000 7000 n(RPM) n(RPM) I (A) at I (A) at n ° (RPM) 1800 RPM 6000 RPM 28V 40A 1000 23 40 28V 45A 1100 22 45 84 28V 50A 1200 22 50 42 94 28V 55A 1250 21 55 30 115 28V 60A 1400 18 60 I (A) at 1800 RPM 6000 RPM 14V 70A 1000 47 70 14V 80A 1100 40 80 14V 85A 1000 47 14V 95A 1100 14V 120A 1400 CONNECTION DIAGRAM D+ B+ B- W DREGULATOR DF D+ G I (A) at n ° (RPM) A LT E R N AT O R S AAN compact APPLICATIONS • for passenger cars and commercial vehicles with higher electrical demand • for heavy-duty applications • for special applications F • • • • • • DESIGN The alternator is a three-phase, 12-pole synchronous self-excited generator with two internal fans and built-in regulator and rectifier. The compact construction and carefully selected materials assure improved technical characteristics and long life, service free, operation even under the harshest conditions of high and low temperatures, salt spray, humidity, water, dust, vibrations, aggressive liquids. MAIN TECHNICAL DATA Type AAN Compact Nominal voltage 14V 28V Nominal current 100A-150A 60A – 100A Stator diameter 142 mm Weight ~7.3 kg without pulley Max. speed Regulator eatures high specific power and efficiency small dimensions low weight low noise level higher protection against accidental contact long life operation 20,000 RPM Built-in or separate Monofunction or multifunction Microelectronic technology Pulleys and drive Different types according to customers' end brackets requirements. Terminals Screw and/or blade terminal Drive end bearings Type 6304E, 62304E Rear end bearings Type 6203 Power diodes Press fit Zener diodes Protection of the slip Protected against ingress of solid foreign rings and brushes matter and powerful water jets (IP 56) Ambient temperature From - 40ºC to + 110ºC Stator The stator has a three-phase winding on a laminated pack. The selected design and high filling factor of the stator slots provides improved cooling, low noise and high output characteristics. Cooling Two internal fans positioned on the claw poles provide more effective cooling with lower noise and higher protection against accidental contact as well as higher output. Rotor Smaller slip rings assure higher brush durability, even at high speeds. Encapsulated slip rings offer increased durability of the alternator. Rectifier Sandwich construction of the rectifier with press fit Zener diodes provides for low temperatures of the rectifier diodes, high resistance to vibrations and protection of loads on the vehicle against alternator overvoltages. The installation of the rectifier on the outer side of the rear end bracket ensures flexible arrangement of all types of terminals. Regulator The regulator together with the brush holder is assembled on the rear end bracket. Regulators use microelectronic technology and are mono or multifunction. The highest quality of brushes ensure long life of the alternator. Bearings - Brackets - Pulleys Brackets, bearings and pulleys are made according to the customers’ requirements. A range of special sealed bearings makes it possible to design alternators for specific installations, operating in the harshest conditions whilst achieving long, maintenance free life. Electrical terminals Electrical terminals are according to the requirements of the customers. A LT E R N AT O R S AAN compact CROSS SECTION 1 2 3 4 5 6 Pos 1 … Pulley Pos 2 … Drive end bearing 13 Pos 3 … Drive end bracket 14 Pos 4 … Stator with winding 12 Pos 5 … Rotor o 142 mm 11 Pos 6 … Rear bracket Pos 7 … Rectifier with diodes 10 Pos 8 … Protective cover 9 Pos 9 … Terminals B+, D+, W Pos 10 …Rear bearing 8 Pos 11 …Slip rings 7 Pos 12 …Brush Pos 13 …Brush holder with voltage regulator 148 mm Pos 14 …Rubber gaskets CHARACTERISTICS I(A) I(A) 160 120 150A 140A 140 105 130A 120A 120 100A 90 100 75 80 60 60 45 80A 70A 30 40 U=const.=13V To=23ºC±5ºC 20 U=const.=27V To=23ºC±5ºC 15 0 0 0 1000 2000 3000 4000 5000 6000 7000 0 1000 2000 3000 4000 5000 6000 7000 n(RPM) n(RPM) I (A) at 1800 RPM 6000 RPM 14V 120A 1050 78 125 14V 130A 1050 80 134 14V 140A 1200 72 145 14V 150A 1200 74 154 CONNECTION DIAGRAM D+ B+ B- I (A) at I (A) at n ° (RPM) 1800 RPM 6000 RPM 28V 70A 1050 41 74 28V 80A 1250 39 85 28V 100A 1250 38 100 W DREGULATOR DF D+ G I (A) at n ° (RPM) A LT E R N AT O R S A AT APPLICATIONS These alternators provide very high output power and are designed to be built into applications requiring high consumption of electrical energy. They were all initially designed for installation on diesel engines in buses and some special purpose applications. DESIGN The alternators are three-phase, 16-pole synchronous generators, self-excited by a rotor consisting of claw poles using protected slip rings. They have a built-in rectifier and regulator and are cooled by an external fan. Design solutions and anticorrosion coatings as well as specially chosen bearings ensure long life without maintenance under normal operating conditions. For operation in extremely hard conditions - temperature, dust, water - it is advisable to ventilate the alternator using a special protection cover on the rear. MAIN TECHNICAL DATA Type AAT Nominal voltage 28V Nominal current 75A-140A Stator diameter 165 mm Weight ~9.6 kg without pulley for 75A ~14.5 kg without pulley for 140A Max. speed 9,000 RPM Regulator Built-in or separate Monofunction Hybrid technology Pulleys and drive Different types according to customers' end brackets requirements Terminals Screw and/or blade terminal Drive end bearings Type 62306-2RS Rear end bearings Type NU 202 Power diodes Press fit Zener diodes Protection of the slip Protected against ingress of solid foreign rings and brushes matter and powerful water jets (IP 56) Ambient temperature From - 40ºC to + 110ºC Cooling The alternator has a built-in fan with axial - radial blades that allow rotation in both directions. It is also possible to use a low-noise fan with specially shaped blades. Stator A three-phase stator winding with a high filling factor of the slots and a special method of assembly provide better cooling and high output power. Rotor The rotor field winding provides excitation of the alternator through slip rings. With regard to the installation requirements, slip rings and brushes are protected in an enclosed environment sealed against dust and water. Rectifier The rectifier stack is a three-phase bridge circuit with built-in press fit power and excitation diodes. Press fit Zener diodes are used to protect alternator and loads on the vehicle against overvoltages. Regulator The regulator together with the brush holder is built into the rear end bracket of the alternator. Regulators are produced in thick-film hybrid technology. Monofunction versions of the regulator only are available. Brackets - Bearings - Pulleys The high quality specially chosen bearings provide long service free life. Electrical terminals Electrical terminals are according to the customers' requirements. A LT E R N AT O R S A AT CROSS SECTION Pulley Pos 2 … Drive end bearing Pos 3 … Fan Pos 4 … Drive end bracket Pos 5 … Stator Pos 6 … Rotor Pos 7 … Rear bracket Pos 8 … Rectifier Pos 9 … Rubber gaskets 2 3 4 5 6 7 8 9 10 11 12 13 o 165 mm Pos 1 … 1 14 15 Pos 10 … Brush Pos 11 … Brush holder with voltage regulator 16 Pos 12 … Oil seal Pos 13 … Rear bearing Pos 14 … Slip rings Pos 15 … Terminals D+, B+, W 227 mm Pos 16 … Capacitor CHARACTERISTIC I(A) 160 140 140A 120 120A 100 105A 95A 80 75A 60 40 U=const.=28V To=23ºC±5ºC 20 0 0 1000 2000 3000 4000 5000 6000 7000 n(RPM) I (A) at I (A) at n ° (RPM) 1800 RPM 6000 RPM 28V 75A 1000 50 75 28V 95A 950 60 95 28V 105A 900 70 105 28V 120A 1020 78 120 28V 140A 1080 90 140 CONNECTION DIAGRAM C B- B+ D- W REGULATOR DF D+ R G D+ product requirements form A LT E R N AT O R S 1. CUSTOMER Company: Address: Country: Responsible person: Phone: Fax: E-mail: 2. ENGINE DATA PROJECT Name: inquiry new project modification 4 th 5 th Brief description: Quantity in next years: 1 st 2 nd 3 rd APPLICATION cars trucks buses agriculture road industry railway marine other applications ENGINE DATA petrol diesel No. of cylinders Rated output kW 2/4 stroke No. of valves Compression Displacement Min. speed RPM Max. speed Ltr. RPM PREDECESSOR / EQUIVALENT TYPE OF ALTERNATOR Supplier Type Drawing Mark Release number 3. ALTERNATOR REQUIREMENTS ELECTRICAL REQUIREMENTS Voltage V Power kW A (1800 min -1 ) Current Isolated ground NO YES Electrical connections B+ type of terminal D+ type of terminal W type of terminal B- type of terminal Other connection - terminals Regulator voltage Ur = Regulator: monofunction Description of function V multifunction A (6000 min -1 ) product requirements form A LT E R N AT O R S MECHANICAL REQUIREMENTS FOR ALTERNATOR Direction of alt. rotation: clockwise Ratio between engine and alternator: counterclockwise both directions 1: Type of driving belt/ pulley: one groove, belt width mm angle two groove, belt width mm dimension between belt angle dimension between grooves angle poly V belt, number of grooves Diameter of the pulley mm Belt line dimension Type of pulley bearing DESIGN REQUIREMENTS Max. diameter: mm Max. length: mm Max. weight: Please draw direction, position of cables, terminals (back side view) Type of installation Other design requirements: Grade of protection according IP (DIN 40050): IP Environmental conditions: salt spray high temperature humidity others Mounting requirements: (to specify/sketch) or enclose drawing Special requirements: Customer test specification No.: Safety standards: Other standards: Vehicle test or bench test (duration/conditions/number of samples): Date: Signature: low temperature kg